chain_11-120-

-006-120, 11-310-120, 11-311-120Status Indicator RAPs

11-005-120, 11-006-120, 11-310-120, 11-311-120 Front • Figure 32, 1K LCSS PWB.

• 11C-120 1K LCSS Power Distribution RAP.

ecessary:

1.

1.

t tamper home sensor, Q11-310. The display

RAP.

ution RAP.

ecessary:

1.112 Item 3.

1.

omponent location

Front tamper home sensor Q11-310

A

July 20052-287WorkCentre Pro 275 Family (CC232-WCP275F) 11-005-120, 11

Tamper Move Failure RAP11-005-120 Front tamper fails to move to the front position.

11-006-120 Front tamper fails to move to the rear position.

11-310-120 Front tamper not at the front home position.

11-311-120 Front tamper not at the rear home position.

Initial ActionsFigure 1. Check for damage or obstructions that would prevent the tamper assembly from operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1.

Jams can be caused by customers removing prints from bin 1 before the machine has finished printing. If the tampers are touched while they are moving, they can be stalled, causing the machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher and the tray 3 and tray 4 to paper path interface.

Check the condition of the front tamper drive belt and that it is correctly tensioned. Tensioning is achieved by a spring on the motor, the motor should be free to move.

If there is a large jam of paper above bin 1 that has obstructed the tampers, this has probably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor. Perform the following:

• Check the paper for defects that could degrade the tamping operation e.g. curl, paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP.

• Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll Fail-ure RAP.

• Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP.

• Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

• Check the 1K LCSS PWB DIP switch settings, refer to 11F-110 1K LCSS PWB DIP Switch Settings RAP.

Procedure

NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-003 and 11-005 alternately. The front tamper moves between the home and inboard positions, Figure 1.Y N

Go to Flag 2. Check the front tamper motor, MOT11-003.Refer to:

• 11G-120 1K LCSS PWB Damage RAP.

• GP 10 How to Check a Motor.

Repair or install new components as n

• Tamper assembly, PL 11.112 Item

• 1K LCSS PWB, PL 11.124 Item

Enter dC330 code 11-310. Actuate the fronchanges.Y N

Go to Flag 1. Check Q11-310.Refer to:

• 11F-120 1K LCSS PWB Damage

• GP 11 How to Check a Sensor.

• P/J16, 1K LCSS PWB.

• 11C-120 1K LCSS Power Distrib


• Front tamper home sensor, PL 1


Perform SCP 6 Final Actions.

Figure 1 C

Front tamper motorMOT11-003 (located at the rear)

A

WorkCentre Pro 275 Family (CC232-WCP275F)
July 2005
2-28811-005-120, 11-006-120, 11-310-120, 11-311-120Status Indicator RAPs

Figure 2 Circuit diagram

-120, 11-312-120, 11-313-120, 11-Status Indicator RAPs

11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 Refer to:

• 11F-120 1K LCSS PWB Damage RAP.

ution RAP.

ecessary:

1.

1.

tamper home sensor Q11-311. The display

e RAP.

ution RAP.

ecessary:

.112 Item 3.

1.

r short edge feed small paper. This saves unneces-

y home sensor Q11-319. The display changes.

e RAP.

ution RAP.

ecessary:

PL 11.112 Item 3.

1.

A

July 20052-289WorkCentre Pro 275 Family (CC232-WCP275F) 11-007-120, 11-008

Rear Tamper Move Failure RAP11-007-120 Rear tamper fails to move to the front position.

11-008-120 Rear tamper fails to move to the rear position.

11-312-120 Rear tamper is not at the front home position.

11-313-120 Rear tamper is not at the rear home position.

11-319-120 Rear tamper is not at the away home position.

NOTE: The away home position is with the rear tamper approximately halfway along it’s travel.

Initial ActionsFigure 1. Check for damage or obstructions that would prevent the tamper assembly from operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1.

Jams can be caused by customers removing prints from bin 1 before the machine has finished printing. If the tampers are touched while they are moving, they can be stalled, causing the machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher and the tray 3 and tray 4 to paper path interface.

Check the condition of the rear tamper drive belt and that it is correctly tensioned. Tensioning is achieved by a spring on the motor, the motor should be free to move.

If there is a large jam of paper above bin 1 that has obstructed the tampers, this has probably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor. Perform the following:

• Check the paper for defects that could degrade the tamping operation e.g. curl, paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP.

• Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll Fail-ure RAP.

• Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP.

• Refer to the 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

• Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

Procedure



Enter dC330, codes 11-004 and 11-006 alternately. The rear tamper moves between the home and inboard positions, Figure 1.Y N

Go to Flag 3. Check the rear tamper motor, MOT11-004.

• GP 10, How to Check a Motor.




• Tamper assembly, PL 11.112 Item


Enter dC330 code 11-311. Actuate the rearchanges.Y N


• 11G-110 1K LCSS PWB Damag

• GP 11, How to Check a Sensor.




• Rear tamper home sensor, PL 11


NOTE: The away home position is used fosary rear tamper travel.

Enter dC330. Actuate the rear tamper awaY N


• 11G-110 1K LCSS PWB Damag





• Rear tamper away home sensor,



A

July 2005
2-29011-007-120, 11-008-120, 11-312-120, 11-313-120, 11-Status Indicator RAPs

Figure 1 Component Location

Rear tamper motorMOT11-004 (located at the front)

Rear tamper away home sensorQ11-319

Rear tamper home sensorQ11-311

-120, 11-312-120, 11-313-120, 11-Status Indicator RAPs
July 2005
2-291WorkCentre Pro 275 Family (CC232-WCP275F) 11-007-120, 11-008



RAP.

ution RAP

ecessary:

1.104 Item 11.

1.

omponent location

Paddle motorMOT11-024

Paddle roll position sensorQ11-326

A

July 20052-29211-024-120, 11-025-120

Status Indicator RAPs

11-024-120, 11-025-120 Paddle Roll Failure RAP11-024-120 The paddle is not at the home position.

11-025-120 The paddle fails to rotate.

NOTE: The home position of the paddle is when the sensor flag is located between the sensor jaws. Jams will occur in the compiler and bin 1 cannot be used.

Initial ActionsCheck the following:

• That there is no paper or other obstructions in the vicinity of the paddle.

• The paddle roll position sensor bracket is holding the sensor in the correct position, i.e. the flag is in the middle of the sensor gap and the sensor does not touch any moving com-ponents.

• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, the compiler capacity can be exceeded. Refer to 11H-120 Mis-Registration in Stapled Sets and Non-stapled Sets RAP.

• Check the position of the paddles. With the paddle roll in the home position both sets of paddles must be within the output cover, if they are not, refer to REP 11.12-120 Paddle Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install a new paddle wheel shaft assembly, PL 11.104 Item 4.

• 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

Procedure



Enter dC330, codes 11-024, paddle home position and 11-025, paddle run. The paddle rotates correctly.Y N

Go to Flag 2. Check the paddle motor, MOT 11-024.Refer to:



• Figure 1.


• 11C-120 1K LCSS Power Distribution RAP

Repair or install new components as necessary:

• Paddle motor, PL 11.104 Item 10.

• 1K LCSS PWB, PL 11.124 Item 1.

Enter dC330, code 11-025 and stack the code 11-326, to actuate the paddle roll position sen-sor Q11-326. The display cycles high/low.Y N

Go to Flag 1. Check Q11-326.

Refer to:



• Figure 1.




• Paddle roll position sensor, PL 1



Figure 1 C

A

11-024-120, 11-025-120Status Indicator RAPs
July 2005
2-293WorkCentre Pro 275 Family (CC232-WCP275F)



RAP.

ution RAP.

ecessary:

-336, PL 11.106 Item 11.

1.

otor, MOT11-030. Bin 1 cycles down and up.

RAP.

ution RAP.

ecessary:

Item 8.

1.

1 upper level sensor, Q11-332. Actuate Q11-332.

RAP.

ution RAP.

ecessary:

2, PL 11.106 Item 5.

1.

pper limit switch, S11-334. Actuate S11-334. The

RAP.

ution RAP.

ecessary:

06 Item 3.

1.

A

July 20052-29411-030-120, 11-334-120, 11-335-120, 11-336-120


11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP11-030-120 Bin 1 fails to move.

11-334-120 Bin 1 has reached the upper limit of travel.

11-335-120 Bin 1 has reached the lower limit of travel.

11-336-120 Bin 1 is not at the home position.

NOTE: The home position of bin 1 is when bin 1 is actuating the bin 1 upper limit switch. See the final actions at the end of the procedure.

Two sensors and two switches monitor the level of paper in bin 1 and the position of the tray

• The bin 1 upper level sensor detects the top of the paper stack in bin 1, Figure 1.

• The bin 1 90% full sensor detects when the tray has descended to a position where the tray is 90% full, Figure 2.

• Bin 1 upper limit switch, S11-334, Figure 2.

• Bin 1 lower limit switch, S11-335, Figure 2.

Initial ActionsPerform the following:

• Check for a physical obstruction that would prevent bin 1 from moving, such as an item of furniture.

• Check that bin 1 is level front to back, if necessary perform ADJ 11.1-120 1K LCSS Bin 1 Level.

• Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

• Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

• If there is a large jam of paper above bin 1, this has probably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor.

Perform the relevant check:

• If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor.

• If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 paper sensor - low and bin 1 paper sensor - high.

Check the front and rear bin 1 drive belts. If necessary install new components, PL 11.106 Item 1.

Procedure



Remove the 1K LCSS rear cover. Enter dC330 code 11-336, bin 1 motor encoder sensor Q11-336. Slowly rotate the encoder disk by hand. The display changes.Y N

Go to Flag 2. Check Q11-336.

Refer to:






• Bin 1 motor encoder sensor Q11


Enter dC330 code 11-033, bin 1 elevator mY N

Go to Flag 1. Check MOT11-030.Refer to:


• GP 10 How to Check a Motor.




• Bin 1 elevator motor, PL 11.106


Figure 1. Enter dC330, code 11-332, binThe display changes.Y N







• Bin 1 upper level sensor Q11-33


Figure 2. Enter dC330 code 11-334, bin 1 udisplay changes.Y N

Go to Flag 4. Check S11-334.Refer to:


• GP 13 How to Check a Switch.




• Bin 1 upper limit switch, PL 11.1


A B


Enter dC330 code 11-335, bin 1 lower limit switch, S11-335, actuate S11-335. The display changes.

omponent location

level 332

B

July 20052-295WorkCentre Pro 275 Family (CC232-WCP275F) 11-030-120, 11

Y NGo to Flag 5. Check S11-335.Refer to:


• GP 13 How to Check a Switch.



• REP 11.13-110 1K LCSS Un-docking.


• Bin 1 lower limit switch, PL 11.106 Item 3.


Enter dC330 code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display changes.Y N







• Bin 1 90% full sensor Q11-331, PL 11.106 Item 5.


As final actions, check the following sequence of operation:

• When bin 1 is empty and at the top, bin 1 upper limit switch, S11-334 is actuated and the bin 1 upper level sensor, Q11-332 is de-actuated.

• Paper is delivered to the tray until the bin 1 upper level sensor, Q11-332 is actuated.

• The motor lowers the tray until the bin 1 upper level sensor, Q11-332 is de-actuated.

• When the tray is emptied, the tray returns to the home position. In the home position the bin one upper limit switch, S11-334 is actuated.

Figure 1 C

Bin 1 upper sensor Q11-


Circuit diagram

July 20052-29611-030-120, 11-334-120, 11-335-120, 11-336-120


Figure 2 Component location

Figure 3

Bin 1 elevator motorMOT11-030

Bin 1 motor encoder sensor Q11-336

Bin 1 90% full sensorQ11-331

Bin 1 upper limit switch S11-334.

Bin 1 lower limit switch S11-335.

July 2005
2-297WorkCentre Pro 275 Family (CC232-WCP275F) 11-030-120, 11

Figure 4 Circuit diagram.


omponent location

Staple head including MOT11-050 and staple head 1 home sensor Q11-360

July 20052-29811-050-120, 11-360-120


11-050-120, 11-360-120 Staple Head Operation Failure RAP11-050-120 The staple head fails to cycle.

11-360-120 The staple head is not at the home position.

NOTE: The home position is with the jaws of the staple head fully open.

Initial ActionsSwitch off the machine, then switch on the machine, GP 14.

Figure 1. Check the following:

• The 1K LCSS PWB DIP switch settings, refer to 11F-110 1K LCSS PWB DIP Switch Set-tings RAP.

• The staple head unit is correctly installed.

Procedure

NOTE: After repairing the fault using this RAP, switch off the machine, then switch on the machine, GP 14, to enable operation of the staple head.



Enter dC330, code 11-050, staple head motor 1, to cycle the staple head once. The staple head operates as expected.Y N

Go to Flag 1 and Flag 2. Check the wiring and connectors between the 1K LCSS PWB and the staple head. The wiring is good.Y N

Repair the wiring.

Perform the following procedures:



Install new components as necessary:

• Staple head unit, PL 11.116 Item 7.


Perform SCP 6 Final Actions.Figure 1 C

July 2005



omponent location

Entry sensorQ11-100

July 20052-30011-100-120


11-100-120 1K LCSS Paper Entry RAP11-100-110 The leading edge of the sheet is late to the entry sensor Q11-100.

Initial ActionsRefer to the 11G-120 Copy Damage in the 1K LCSS RAP.

Check the following:


• Ensure the paper tray guides are set to the correct position for the size of paper in the tray.

• Check the input guide for damage or wear that could cause paper to jam.

• Paper jam in the machine to 1K LCSS paper path.

• IOT exit path and feed rolls.

• Feeding performance from a paper tray loaded with a new ream of paper.

Procedure


Figure 1. Lower the paper entry guide assembly, PL 11.110 Item 8, to access the entry sensor. Enter dC330, code 11-100, entry sensor, Q11-100. Actuate Q11-100. The display changes.Y N







• Entry sensor, PL 11.122 Item 3.



Figure 1 C


11-130-120, 11-132-120 Paper Exiting to Bin 0 RAPis late to the top exit sensor.

s late from the top exit sensor.

efer to 11E-120 1K LCSS PWB DIP Switch Settings

t to the correct position for the size of paper in the

per drive belt. Check that the tensioner is free to free to rotate. If necessary lubricate the tensioner efer to GP 18 Machine Lubrication.

nsioner pulley require different lubricants, refer to

ort motor 1 and 2 are secure and do not slip on the

orrectly fitted and are in a good condition

lleys are free to rotate.

movement.

jam clearance action.

1K LCSS RAP and the 11H-120 Mis-Registration in

diverter gate solenoid is energized. Paper is fed to -energized.

de to supply +24V to the motors.

SS sensor or switch can change the displayed state r or switch is tested.

2, MOT11-001, Figure 1. MOT11-001 runs.

RAP.

ution RAP.

ecessary:

m 5.

1.

July 20052-301WorkCentre Pro 275 Family (CC232-WCP275F) 11


11-130-120 The leading edge of the sheet

11-132-120 The trailing edge of the sheet i

Initial ActionsCheck the following:

• 1K LCSS PWB DIP switch settings, rRAP.

• Ensure the paper tray guides are setray.

• The tensioner on the intermediate pamove and that the tensioner pulley isand tensioner pulley, REP 11.3-120. R

NOTE: The tensioner arm and the teREP 11.3-120.

• That the drive pulleys on both transpmotor shaft.

• That all the transport drive belts are c

• That all the transport rolls and idler pu

• The diverter gate and linkage for free

• A paper jam in the path to bin 0.

• Torn paper fragments from a previous

Refer to the 11G-120 Copy Damage in theStapled Sets and Non-Stapled Sets RAP.

NOTE: Paper is diverted to bin 0 when thebin 1 when the diverter gate solenoid is de

Procedure

NOTE: All 1K LCSS interlocks must be ma

NOTE: In diagnostics, actuating any 1K LCon the UI. Make sure that the correct senso

Enter dC330, code 11-001 transport motorY N







• Transport motor 2, PL 11.118 Ite


A


omponent location

Top exit sensor Q11-130

Diverter gate solenoid S11-002

Transport motor 2 MOT11-001

Transport motor 1 MOT 11-000

A

July 20052-30211-130-120, 11-132-120


NOTE: The diverter gate solenoid remains energized for 5 seconds.

Enter dC330, code 11-002 diverter gate solenoid, SOL11-002. SOL11-002 energizes.Y N

Go to Flag 2. Check SOL11-002.Refer to:


• GP 12, How to Check a Solenoid.




• Diverter gate solenoid, PL 11.118 Item 12.


Enter dC330, code 11-130, top exit sensor, Q11-130. Actuate Q11-130. The display changes.Y N







• Top exit sensor, PL 11.118 Item 11.


Enter dC330, code 11-000, transport motor 1, MOT11-000. MOT11-000 runs.Y N







• Transport motor 1, PL 11.110 Item 2.


Perform SCP 6 Final Actions.Figure 1 C

July 2005



RAP.

ution RAP.

ecessary:

m 5.

1.

d, SOL11-002. SOL11-002 energizes.

RAP.

.

ution RAP.

ecessary:

Item 12.

.

ensor, Q11-140. Actuate Q11-140. The display

RAP.

ution RAP.

ecessary:

Item 4.

1.

1, MOT11-000. MOT11-000 runs.

RAP.

ution RAP.

ecessary:

m 2.

1.

A

July 20052-30411-140-120, 11-142-120


11-140-120, 11-142-120 Sheet Late to Bin 1 RAP11-140-120 The leading edge of the sheet is late to the 2nd to top exit sensor.

11-142-120 The trailing edge of the sheet is late to the 2nd to top exit sensor.

Initial Actions

NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Paper is fed to bin 1 when the diverter gate solenoid is de-energized.



• Ensure the paper tray guides are set to the correct position for the size of paper in all trays.

For trays 3 and 4, perform the following:

– Select the systems settings button from the tools screen.

– Select the tray management button and stock settings.

– From the list, select tray 3. Select the change stock size button.

– Select the paper size loaded in the tray. Select the save button.

– Repeat for tray 4.

– Save the stock setting and exit the tools mode.

• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to move and that the tensioner pulley is free to rotate. If necessary re-lubricate the tensioner and tensioner pulley, REP 11.3-120.

NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to REP 11.3-120 for details

• That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the motor shaft.

• That all the transport drive belts are correctly fitted and are in a good condition

• That all the transport rolls and idler pulleys are free to rotate.

• The diverter gate and linkage for free movement.

• A paper jam in the path to bin 1, to the compiler, and for poor stacking on bin 1.

• Ensure that the 1K LCSS is fully latched to the machine, refer to REP 11.11-120.

• Torn paper fragments from a previous jam clearance action.

Refer to the 11G-120 Copy Damage in the 1K LCSS RAP and the 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

Procedure



Figure 1. Enter dC330, code 11-001 transport motor 2, MOT11-001. MOT11-001 runs.Y N

Go to Flag 3. Check MOT11-001.

Refer to:


• GP 10, How to check a motor.






Enter dC330, code 11-002 diverter solenoiY N

Go to Flag 4. Check SOL11-002.Refer to:


• GP 12, How to Check a Solenoid




• Diverter gate solenoid, PL 11.22

• 1K LCSS PWB, PL 11.26 Item 1

Enter dC330, code 11-140 2nd to top exit schanges.Y N



• GP 11, How to Check a sensor.




• 2nd to top exit sensor, PL 11.120


Enter dC330, code 11-000 transport motorY N









A B


Perform SCP 6 Final Actions.B

July 20052-305WorkCentre Pro 275 Family (CC232-WCP275F)



Diverter gate solenoidS11-002

2nd to top exit sensor Q11-140


July 2005
2-30611-140-120, 11-142-120Status Indicator RAPs



11-300-120, 11-302-120, 11-303-120 Interlocks RAP • If necessary, install a new docking interlock switch, PL 11.102 Item 2.

RAP02 as follows:

r interlock switch, S11-302. Actuate S11-302. If the

n P/J5 and S11-302.

terlock switch, PL 11.124 Item 6.

RAP303 as follows:

r interlock switch, S11-303. Actuate S11-303. If the

n P/J5 and S11-303.

nterlock switch, PL 11.124 Item 5.

July 20052-307WorkCentre Pro 275 Family (CC232-WCP275F) 11

11-300-120 The docking interlock is open during run mode.

11-302-120 The top cover interlock is open during run mode.

11-303-120 The front door interlock is open during run mode.

Initial ActionsCheck the 1K LCSS PWB DIP switch settings, refer to 11F-110 1K LCSS PWB DIP Switch Set-tings RAP.


• The 1K LCSS is installed correctly, refer to REP 11.13-120.

• The 1K LCSS front door is closed.

• The 1K LCSS top cover is closed.

Procedure


Go to Flag 1. Check for +24V on P/J5 pin 1. If the voltage is not present, refer to 11C-120 1K LCSS Power Distribution RAP.

Go to the appropriate RAP:

• 11-300-120 Docking Interlock RAP

• 11-302-120 Top Cover Interlock RAP

• 11-303-120 Front Door Interlock RAP

11-300-120 Docking Interlock RAPWARNING

Take care not to topple the LCSS.

The LCSS is unstable when undocked from the machine.

Do not show the customer how to undock the LCSS.

Undock the 1K LCSS, refer to REP 11.11-120. Figure 1, check the docking interlock switch, S11-300 as follows:

• While supporting the 1K LCSS, slide the 1K LCSS 5cm (2 inches) away from the machine. Check the interlock actuator on the machine is not damaged or missing.

NOTE: The wiring harness passes underneath the docking interlock switch housing. If this harness is not correctly positioned, the switch can be mis-located, giving intermittent docking interlock problems.

• Enter dC330, code 11-300, docking interlock switch, S11-300. While supporting the 1K LCSS, slide the 1K LCSS 5cm (2 inches) away from the machine to de-actuate S11-300. If the display does not change, refer to:

– GP 13, How to Check a Switch

– P/J6, 1K LCSS PWB.

• Go to Flag 1. Check the wiring between P/J5 and S11-300.

11-302-120 Top Cover Interlock Check the top cover interlock switch, S11-3

• Check the switch actuator.

• Enter dC330, code 11-302, top covedisplay does not change, refer to:

– GP 13, How to Check a switch

– Figure 2.


• Go to Flag 3. Check the wiring betwee

• If necessary, install a new top cover in

11-303-120 Front Door InterlockCheck the front door interlock switch, S11-

• Check the switch actuator.

• Enter dC330, code 11-303, front doodisplay does not change, refer to:

– GP 13, How to Check a switch

– Figure 2.


• Go to Flag 2. Check the wiring betwee

• If necessary, install a new front door i



omponent location

Top cover interlock switch S11-302

Front door interlock switch S11-303

July 20052-30811-300-120, 11-302-120, 11-303-120



Figure 2 C

Docking interlock switch S11-300

July 2005
2-309WorkCentre Pro 275 Family (CC232-WCP275F) 11



1.

eration of the ejector motor, MOT11-020. MOT11-

RAP.

ution RAP.

ecessary:

1.

1.

the end stops.

s are correctly formed, refer to the 11-364-120 Sta-s can cause the set to hang in the stapler causing s are correctly formed.

-formed staples, then check the operation of the sta-taple head unit, PL 11.116 Item 5.

a new ejector assembly, PL 11.114 Item 1.

tween pins 7 and 8.

istribution RAP.

en pins 8 and 9. Slowly rotate the ejector motor 5V and 0V.

nnectors between the ejector motor encoder sensor y repair the wiring, REP 1.2. If the wiring is good, nsor, PL 11.118 Item 3.

ge RAP, if necessary install a new 1K LCSS PWB,

A

July 20052-31011-320-120, 11-322-120


11-320-120, 11-322-120 Ejector Movement Failure RAP11-320-120 The ejector is not at the home position.

11-322-120 The ejector fails to perform a cycle of operation.

NOTE: A cycle of operation for the ejector is to cycle from the home position to the out position and back to the home position.

Initial ActionsCheck the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

Check for any obstructions that would prevent the ejector from moving.

Procedure



NOTE: For clarity, the 1K LCSS is shown removed from the machine in Figure 1.

Enter dC330, code 11-322, ejector out sensor, Q11-322. Actuate Q11-322. The display changes.Y N




• Figure 1.




• Ejector out sensor, Q11-322, PL 11.114 Item 3.


Enter dC330, code 11-320, ejector home sensor, Q11-320. Actuate Q11-320. The display changes.Y N




• Figure 1.




• Ejector home sensor, Q11-320, PL 11.114 Item 3.


Enter dC330, code 11-023 to check the op020 runs.Y N




• Figure 1.



Repair or Install new components as n

• Ejector assembly, PL 11.114 Item


The ejector cycles noisily, colliding withY N

Check the stapler to ensure the staplepling Failure RAP. Mis-formed stapleejector movement failures. The stapleY N

Clear the staple head of any mispler. If necessary, install a new s

If the ejector is still not moving, installPerform SCP 6 Final Actions.

Go to Flag 4. +5V is available at P/J8 beY N

Go to the 11C-120 1K LCSS Power D

Connect a service meter at P/J8 betweencoder. The voltage changes between +Y N

Go to Flag 4. Check the wiring and coand the 1K LCSS PWB. If necessarinstall a new ejector motor encoder se

Perform the 11F-120 1K LCSS PWB DamaPL 11.124 Item 1.

A

July 2005


Ejector out sensor Q11-322

Ejector motor MOT11-020

Ejector motor encoder sensor

Ejector home sensor Q11-320

July 2005
2-31211-320-120, 11-322-120Status Indicator RAPs


11-364-120Status Indicator RAPs

11-364-120 Stapling Failure RAP Y NInstall a new staple cartridge, PL 26.10 Item 11 and repeat the check. If the first two sta-

new stapler assembly, PL 11.116 Item 1. Perform

em 5. Perform SCP 6 Final Actions.

omponent location

SH 1 paper sensor Q11-361


11-364-120 Staples in the stapling head are not primed.

Initial ActionsSwitch off the machine, then switch on the machine, GP 14.

Check the 1K LCSS PWB DIP switch settings, refer to 11F-110 1K LCSS PWB DIP Switch Set-tings RAP.


• The staple cartridge has staples in it and is correctly installed,

• The leading staples in the staple head have been primed, Figure 3.

• Check that the sheets of staples in the cartridge are feeding one at a time. If staple sheets overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL 26.10 Item 11.

NOTE: The term “priming” refers to 2 staples at the front of the cartridge, that have been pre-formed automatically by the action of the stapler, refer to Figure 2.

NOTE: The SH 1 low staples sensor, SH 1 cartridge sensor, SH 1 home sensor and the SH 1 priming sensor are all integral to the staple head unit and although they can be checked using component control they cannot be exchanged as components.

ProcedureFigure 1. Enter dC330, code 11-361, SH 1 paper sensor, Q11-361. Actuate Q11-361. The display changes.Y N







• SH 1 paper sensor, PL 11.116 Item 4.


NOTE: If the SH1 priming sensor does not see staples in the primed position, the staple head cycles a number of times to prime the staple head. This occurs when the 1K LCSS interlocks are made.

Follow the customer instruction label inside the 1K LCSS front door to remove the staple car-tridge, slide out the top sheet of staples from the cartridge, to expose a fresh sheet of staples on the top of the stack. Ensure the forming plate is fully closed, Figure 2. Install the staple car-tridge and close the door. The stapler will now cycle a few times to feed and prime the new sheet of staples. Open the door and remove the staple cartridge. Examine the sheet of staples that have been fed to the staple forming part of the stapler, by opening the forming plate, Fig-ure 3. The first two staples have been partially formed.

ples are not partially formed, install aSCP 6 Final Actions

Install a new staple head unit, PL 11.116 It

Figure 1 C

Staple head unit


ple cartridge closed

closed

July 20052-31411-364-120


Figure 2 Staple cartridge open Figure 3 Sta

Primed staplesForming plate open Forming plate fully

11-364-120Status Indicator RAPs
July 2005



Circuit diagram

July 20052-31611A-120


11A-120 Bin 1 Overload RAPUse this RAP to resolve a fault on the bin 1 90% full sensor.

Procedure


Enter dC330, code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display changes.Y N



• GP 11, How to Check a sensor.

• Figure 1.


• 11C-120 1K LCSS Power Generation RAP.


• Bin 1 90% full sensor, PL 11.106 Item 5.




Figure 2

Bin 1 90% full sensor Q11-331

11B-120Status Indicator RAPs

11B-120 Initialization Failure RAP

1 LED location


When an initialization command is received from the machine, the units are initialized in two stages:

• The following units are initialized sequentially:

1. If the staple head is not at the home position, it is driven to the home position

2. If the ejector is not at the home position, it is driven to the home position

• The following units are then initialized simultaneously:

1. If the front tamper is not at the home position, it is driven to the home position

2. If the rear tamper is not at the home position, it is driven to the home position

3. If the paddle is not at the home position, it is driven to the home position

4. If the stacker is not at the home position, it is driven to the home position

NOTE: The staple cartridge must be fully pushed home.

Initial ActionsCheck the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

Remove the 1K LCSS covers, REP 11.1-120, so that the units can be viewed. Cheat the front door interlock switch and the top cover interlock switch. Check that LED 2 is illuminated, this shows that all interlocks are made. If the LED fails to illuminate, go to 11-300-120, 11-302-120, 11-303-120 Interlocks RAP.

ProcedureFigure 1. Check that the software heartbeat is present on LED 1. The LED should flash twice per second if the 1K LCSS software is running. If necessary, re-load the 1K LCSS software, refer to GP 4 Machine Software.

If the initialization sequence fails to place any unit at the home position, refer to the appropriate RAPs:

• Front tamper not at home, refer to 11-005-120, 11-006-120, 11-310-120, 11-311-120 Front Tamper Move Failure RAP

• Rear tamper not at home, refer to 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 Rear Tamper Move Failure RAP.

• Paddle not at home, refer to 11-024-120, 11-025-120 Paddle Roll Failure RAP.

• Bin 1 not at home, refer to 11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Move-ment Failures RAP.

• Staple head not at home, refer to 11-050-120, 11-360-120 Staple Head Operation Failure RAP.

• Ejector not at home, refer to 11-320-120, 11-322-120 Compiler Ejector Movement Failure RAP.

Figure

LED 2 LED 1


. Re-connect the circuits one at a time. Energize the dC330 control codes.

switch off the machine, GP 14. Re-check the com-ting or short circuits. Repair or install new compo-

on the 1K LCSS PWB.

/J6 between pins 4 and 6, also between pins 7

le at P/J6 between pins 4 and 6, also between harness.

e 1K LCSS power cord from PJ22. ACL is avail- 1 and 3 on the LVPS and base module.

er RAP.

11.12-120. Loosen the 2 screws and lift the power he 1K LCSS frame. Go to Flag 1. Check the wiring e wiring is good.

module, PL 11.124 Item 2.

an overload in the wiring or components connected S PWB. Refer to GP 7.

SS PWB Damage RAP, if necessary install a new Item 1.

Damage RAP, if necessary install a new 1K LCSS

S PWB are good.

A

July 20052-31811C-120


11C-120 1K LCSS Power Distribution RAPThe 1K LCSS has an integral power supply providing +24V and +5V supplies to the 1K LCSS PWB. The AC power for the 1K LCSS power supply comes from the LVPS and base module of the machine.

CAUTION

Do not connect the finisher power cord directly to the AC wall outlet. The finisher cannot oper-ate without the machine. The machine controls the distribution of electricity to the finisher for correct power on and power off sequencing.

ProcedureWARNING

Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.

Close or cheat all the 1K LCSS interlocks. LED 2 on the 1K LCSS PWB is illuminated.Y N

Go to Flag 2. +24V is available at P/J6 between pins 1 and 2, also between pins 5 and 3.Y N

Disconnect P/J6. +24V is available at P/J6 between pins 1 and 2, also between pins 5 and 3 on the end of the harness.Y N

Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22. ACL is avail-able at PJ22 between pins 1 and 3 on the LVPS and base module.Y N

Go to the 01C AC Power RAP.

Remove the 1K LCSS, REP 11.12-120. Loosen the 2 screws and lift the power supply module away from the 1K LCSS frame. Go to Flag 1. Check the wiring between CN2 and P/J6. The wiring is good.Y N

Repair the wiring.

Install a new power supply module, PL 11.124 Item 2.

Perform the following:

• Check for a short circuit or an overload in the wiring or components connected to the +24V on the 1K LCSS PWB. Refer to GP 7.

• Perform the 11F-120 1K LCSS PWB Damage RAP, if necessary install a new 1K LCSS PWB, PL 11.124 Item 1.

+24 V is available at P/J5 pin 3 on the 1K LCSS PWB. Y N

Go to the 11-300-120, 11-302-120, 11-303-120 Interlocks RAP.

Perform the following: • Switch off the machine, GP 14.

• Go to Flag 3. Disconnect all the +24V harnesses to components.

• Check each harness for short circuits and overheating, GP 7.

• Repair or install new components as necessary.

• Monitor the voltage at P/J6 pin 1re-connected components using

• If the voltage drops below +22V,ponent and harness for overheanents as necessary.

+5V is available between TP3 and TP4 Y N

Go to Flag 2. +5V is available at Pand 8.Y N

Disconnect P/J6. +5V is availabpins 7 and 8 on the end of the Y N

Go to Flag 1. Disconnect thable at PJ22 between pinsY N

Go to the 01C AC Pow

Remove the 1K LCSS, REPsupply module away from tbetween CN2 and P/J6. ThY N

Repair the wiring.

Install a new power supply

Perform the following:

• Check for a short circuit or to the +24V on the 1K LCS

• Perform the 11F-120 1K LC1K LCSS PWB, PL 11.124

Perform the 11F-120 1K LCSS PWBPWB, PL 11.124 Item 1.

The +24V and +5V supplies on the 1K LCS

A

11C-120Status Indicator RAPs
July 2005


Power Supply Module

July 2005
2-32011C-120Status Indicator RAPs


11D-120, 11E-120Status Indicator RAPs

11D-120 1K LCSS to Machine Communications Interface 11E-120 1K LCSS PWB DIP Switch Settings RAPitches on the 1K LCSS PWB.

switch settings are:

e 1K LCSS and/or the machine exit area.

LCSS and machine.

necessary, switch off the machine, GP 14. Correct achine, GP 14.

IP switch settings


RAPAll communications between the machine and 1K LCSS are conducted through a single inter-face cable.

ProcedureCheck the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings RAP.

Go to 03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error Rap.

To show the correct settings for the DIP sw

ProcedureProblems that can result from incorrect DIP

• False jam clearance instructions for th

• Communication errors between the 1K

• Erratic behaviour of the 1K LCSS.

Check the DIP switch settings, Figure 1. Ifthe DIP switch setting, then switch on the m

Figure 1 D


PWB Drive Components

istance ent +/- 10%

Spared part and references

28 ohms. 28 ohms. 28 ohms. 28 ohms.

Paddle motor assembly, PL 11.104 Item 10.11-024-120, 11-025-120 RAP

= 12.6 ohms.= 12.6 ohms

Staple head unit, PL 11.116 Item 5.11-050-120, 11-360-120 RAP

6.4 ohmsBin 1 elevator motor, PL 11.10 Item 8.11-030-120, 11-334-120, 11-335-120, 11-336-120 RAP

20 ohms. 20 ohms. 20 ohms. 20 ohms.

Tamper assembly, PL 11.16 Item 1.11-005-120, 11-006-120, 11-310-120, 11-311-120 RAP

20 ohms.= 20 ohms. = 20 ohms.= 20 ohms.

Tamper assembly, PL 11.112 Item 1. 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 RAP

2.2 ohms. 2.2 ohms. 2.2 ohms. 2.2 ohms.

Transport motor 1, PL 11.110 Item 2.11-130-120, 11-132-120 RAP

6.6 ohmsEjector assembly, PL 11.114 Item 1.11-320-120, 11-322-120 RAP

= 0.8 ohms. = 0.8 ohms. = 0.8 ohms. = 0.8 ohms.

transport motor 2, PL 11.118 Item 5.11-130-120, 11-132-120 RAP

2 = 74 ohmsDiverter gate solenoid, PL 11.118 Item 12.11-130-120, 11-132-120 RAP

July 20052-32211F-120


11F-120 1K LCSS PWB Damage RAPUse this RAP to determine the cause of damage to the 1K LCSS PWB, so that the cause can be repaired before a new 1K LCSS PWB is installed.

ProcedureThe 1K LCSS PWB can be damaged by a component connected to it going short-circuit. If a new 1K LCSS PWB is installed and power applied to the machine, the new 1K LCSS PWB will be damaged in the same way. The cause of the damage must be found by following this proce-dure.

WARNINGSwitch off the electricity to the machine, GP 14. Disconnect the power cord. Electricity can cause death or injury. Moving parts can cause injury.

Remove the 1K LCSS PWB and inspect the components shown in Figure 1 for damage. The damage to the component may be in the form of a crack, a small crater or a burnt patch. Refer to Table 1 to locate the component causing the damage to the 1K LCSS PWB.

Figure 1 1K LCSS PWB components

Table 1 1K LCSS

1K LCSS PWB component

Driven component

Normal resmeasurem

U5 Paddle motor (MOT11024)

At PJ14:Pin 1 to 3 =Pin 1 to 4 =Pin 2 to 5 =Pin 2 to 6 =

U10 Staple head motor (MOT11-050)

At PJ7:Pin 8 to 10 Pin 9 to 11

U11 Bin 1 elevator motor (MOT11-030)

At PJ12:Pin 1 to 2 =

U12 Front tamper motor (MOT11-003)


U13 Rear tamper motor (MOT11-004)

At PJ9:Pin 7 to 9 =Pin 7 to 10 Pin 8 to 11 Pin 8 to 12

U14 Transport motor 1 (MOT11-000)


U15 Ejector motor (MOT11-020)

At PJ15:Pin 1 to 2 =

U16 Transport motor 2 (MOT11-001)

At PJ16:Pin 10 to 12Pin 10 to 13Pin 11 to 14Pin 11 to 15

Q1 Diverter gate solenoid (S11-002)

At PJ13:Pin 1 to pin

11F-120, 11G-120Status Indicator RAPs

NOTE: If difficulty is found in connecting the service meter probes to the connector headers on the 1K LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another

11G-120 Copy Damage in the 1K LCSS RAPuses of copy damage in the 1K LCSS.

ARNING, GP 14. Disconnect the power cord. Electricity

can cause injury.

aper path. Torn fragments can migrate through the t causing a problem until they finally wedge them-

ly, PL 11.118 Item 13, operates correctly and has it’s

, PL 11.122 Item 6, closes and latches correctly. located and functions correctly, the clip at the front can stub on the middle guide.

SS paper path are free to rotate, particularly those paper turns through 90 degrees.

e jam clearance guide, PL 11.122 Item 6, and the are free of “scores” and “nicks”. Check also for con-


point in the harness to the driven component.

If the defective driven component is found using the table checks, disconnect the connector closest to the driven component, then check the driven component again to identify any short circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-sary.

If the defective driven component can not be found using the table checks, refer to GP 7, check each driven component to ensure that it is not seized. Motors should rotate reasonably easily. Solenoid armatures should slide easily in the coil. Also check the drive components to ensure that they rotate easily, if necessary install new parts.

When the a new driven component has been installed or the defective drive components have been repaired, install a new 1K LCSS PWB, PL 11.26 Item 1.

Use this RAP to identify and correct the ca

ProcedureW

Switch off the electricity to the machinecan cause death or injury. Moving parts


• Look for torn paper in the 1K LCSS pIOT and 1K LCSS paper path withouselves at some point.

• Ensure that the shaft diverter assembfull movement.

• Ensure that the jam clearance guideCheck that the magnet at the rear is operate correctly, otherwise the paper

• Ensure that all idler rolls in the 1K LCon the jam clearance guide, where the

• Ensure that the paper path ribs of thentry guide cover, PL 11.124 Item 5, tamination and glue from label stock.


cking RAPking in the 1K LCSS.

ck fully in bin 1 and therefore not operating the bin 1

stacked on top of small paper sizes.

ch paper tray has been fanned.

h paper tray.

opy stock being used is within the size and weight aper and Media Size Specifications.

all paper trays are adjusted correctly for the paper losed.

ctly and the bin 1 alignment clip is in position, PL

bin 0 only.

s are fed to bin 0 whenever possible.

, if necessary perform ADJ 11.1-120 1K LCSS Bin 1

r, Q11-332 is working correctly. Refer to the 11-030--120 Bin 1 Movement Failure RAP.

rear tampers. Refer to 11-005-120, 11-006-120, 11-ove Failure RAP and 11-007-120, 11-008-120, 11-

ar Tamper Move Failure RAP.

osition near a air conditioning or ventilation output

s can cause poor stacking.

July 20052-32411H-120, 11J-120


11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAPUse this RAP to identify and correct the causes of mis registration in stapled sets, resulting in staples missing some sheets in the set, or poorly registered non-stapled sets.

ProcedureWARNING

Switch off the electricity to the machine, GP 14. Disconnect the power cord. Electricity can cause death or injury. Moving parts can cause injury.

The most likely cause of mis registration is paper condition and/or damage such as curl, wrin-kle, creases, dog ears, etc.

Curl, wrinkle and creases are probably caused in the IOT, go to the IQ1 Image Quality Entry RAP.

For other copy/print damage and dog ears, go to the 11G-120 Copy Damage in the 1K LCSS RAP.


• Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.100 Item 13.

• Turn over the paper stack in the tray in use.

• Use a new ream of paper in the tray in use.

• Paper type especially recycled paper can lead to registration problems. Try changing to a different brand or type of paper.

• Ensure that the guides in the paper trays are correctly set and reported on the UI for the paper size loaded.

• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, the compiler capacity can be exceeded.

• Check for obstructions in the compiler.

• Ensure that the paddle roll operates correctly and that the paddles are not damaged. The paddles should park completely inside the top section of the compiler, with the shorter paddle in a vertical position. If all of the paddles are out of position, check the paddle roll position sensor, PL 11.104 Item 11, the flag, PL 11.104 Item 7 and the paddle motor assembly, PL 11.104 Item 10. If only one paddle is mis-aligned with the others, it can be re-positioned by hand (they are not bonded to the shaft).

• Ensure that the tampers operate correctly, i.e. are not stalling or losing position during the job. Inspect the tampers for damage, if necessary install new parts. PL 11.112.

• Inspect the bin 1 entry nips for roll damage. The idlers should be held against the rubber driving rolls and they should be free to rotate within their support springs. If necessary, install new parts, PL 11.120.

• Inspect the four spring loaded guides on the output cover, PL 11.100 Item 7. Ensure that they are correctly located and are free to move up and down.

11J-120 1K LCSS Poor StaUse this RAP to find the cause of poor stac

ProcedureCheck the following;

• Look for sets that are not dropping balevel sensors:

– Large paper sizes should not be

– Ensure that the paper stack in ea

– Turn over the paper stack in eac

– Ensure that all paper or other cspecifications. Refer to GP 20 P

– Try using a fresh ream of paper.

– Ensure that the edge guides of size and that the trays are fully c

– Check that bin 1 is seated corre11.100 Item 13.

• Labels must not be fed to bin 1, but to

• It is recommended that transparencie

• Check that bin 1 is level front to backLevel.

• Check that the bin 1 upper level senso120, 11-334-120, 11-335-120, 11-336

• Check the operation of the front and 310-120, 11-311-120 Front Tamper M312-120, 11-313-120, 11-319-120 Re

• Check that the output device is not p

ducts. Air blown across the output bin

chain_11-120-

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